Vertiv IM60017372 User manual

Type
User manual
eSurePower Extend Converter
Mounting Bracket and Door Kit
Installation Manual
Kit Specification Number: 60017372
Vertiv™ eSurePower Extend Converter Mounting Bracket and Door Kit Installation Manual
Vertiv™ eSurePower Extend Converter Mounting Bracket and Door Kit Installation Manual
The information contained in this document is subject to change without
notice and may not be suitable for all applications. While every precaution has
been taken to ensure the accuracy and completeness of this document, Vertiv
assumes no responsibility and disclaims all liability for damages resulting from
use of this information or for any errors or omissions. Refer to other local
practices or building codes as applicable for the correct methods, tools, and
materials to be used in performing procedures not specifically described in
this document.
The products covered by this instruction manual are manufactured and/or
sold by Vertiv. This document is the property of Vertiv and contains
confidential and proprietary information owned by Vertiv. Any copying, use or
disclosure of it without the written permission of Vertiv is strictly prohibited.
Names of companies and products are trademarks or registered trademarks of
the respective companies. Any questions regarding usage of trademark
names should be directed to the original manufacturer.
Technical Support Site
If you encounter any installation or operational issues with your product, check the pertinent section of this
manual to see if the issue can be resolved by following outlined procedures.
Visit https://www.vertiv.com/en-us/support/ for additional assistance.
Vertiv™ eSurePower Extend Converter Mounting Bracket and Door Kit Installation Manual
Proprietary and Confidential © 2023 Vertiv Group Corp.
iii
TABLE OF CONTENTS
Admonishments Used in this Document ............................................................................................................................. iv
Important Safety Instructions .................................................................................................................................................. v
Safety Admonishments Definitions .......................................................................................................................................................................................................................... v
Safety and Regulatory Statements ........................................................................................................................................................................................................................... v
Déclarations de Sécurité et de Réglementation ........................................................................................................................................................................................... v
1 Vertiv™ eSure™ Power Extend Converter Mounting Bracket and Door Kit Installation
Instructions ...............................................................................................................................................................................1
1.1 Kit Description .................................................................................................................................................................................................................................................................. 1
1.2 Tools and Material Required ............................................................................................................................................................................................................................... 1
1.3 Mounting Bracket and Door Kit Contents ............................................................................................................................................................................................. 2
1.4 Mounting Bracket and Door Kit Installation Procedure ............................................................................................................................................................ 3
1.4.1 Important Safety Instructions ..................................................................................................................................................................................................... 3
1.4.2 Installing Mounting Bracket and Door Kit P/N 60017372 ................................................................................................................................. 3
2 Installing the Power Extend Converter into a Distribution Position ................................................................. 10
2.1 Important Safety Instructions ......................................................................................................................................................................................................................... 10
2.2 Restrictions ...................................................................................................................................................................................................................................................................... 10
2.3 Preparing the Distribution Cabinet ............................................................................................................................................................................................................ 11
2.4 Installing the Power Extend Converter(s)............................................................................................................................................................................................ 13
Vertiv™ eSurePower Extend Converter Mounting Bracket and Door Kit Installation Manual
Proprietary and Confidential © 2023 Vertiv Group Corp.
iv
Admonishments Used in this Document
DANGER
! Warns of a hazard the reader will be exposed to that will likely result
in death or serious injury if not avoided. (ANSI, OSHA)
WARNING
! Warns of a potential hazard the reader may be exposed to that could
result in
death or serious injury if not avoided. This admonition is not used for situations that pose a
risk only to equipment, software, data, or service. (ANSI)
CAUTION
! Warns of a potential hazard the reader may be exposed to that could
result in minor or moderate injury if not avoided. (ANSI, OSHA) This admonition is not
used for situations that pose
a risk only to equipment, data, or service, even if such use
appears to be permitted in some of the applicable standards. (OSHA)
ALERT
! Alerts the reader to an action that must be avoided in order to protect
equipment, software, data, or service. (ISO)
ALERT
! Alerts the reader to an action that must be performed in order to prevent
equipment damage, software corruption, data loss, or service interruption. (ISO)
FIRE SAFETY
! Informs the reader of fire safety information, reminders, precautions,
or policies, or of the locations of fire
-fighting and fire-safety equipment. (ISO)
SAFETY
! Informs the reader of general safety information, reminders, precautions, or
policies not
related to a particular source of hazard or to fire safety. (ISO, ANSI, OSHA)
Vertiv™ eSurePower Extend Converter Mounting Bracket and Door Kit Installation Manual
Proprietary and Confidential © 2023 Vertiv Group Corp.
v
Important Safety Instructions
Safety Admonishments Definitions
Definitions of the safety admonishments used in this document are listed under “Admonishments Used in this Document” on page iv.
Safety and Regulatory Statements
Refer to Section 4154 (provided with your customer documentation) for Safety and Regulatory Statements.
Déclarations de Sécurité et de Réglementation
Reportez-vous à la Section 4154 (fourni avec les documents de votre client) pour les déclarations de sécurité et de réglementation.
Vertiv™ eSurePower Extend Converter Mounting Bracket and Door Kit Installation Manual
Proprietary and Confidential © 2023 Vertiv Group Corp.
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Vertiv™ eSurePower Extend Converter Mounting Bracket and Door Kit Installation Manual
Proprietary and Confidential © 2023 Vertiv Group Corp.
1
1 VertiveSure™ Power Extend Converter Mounting Bracket
and Door Kit Installation Instructions
1.1 Kit Description
Mounting bracket kits have been designed to easily install a Vertiv™ eSure™ Power Extend Converter (Model C48/58-1000B, Spec.
No. 1C48581000B) into a distribution position of a Vertiv™ NetSure™ Power System (see UM565050 for kit part numbers and
descriptions). A mounting bracket kit must be used for grounding and mechanical support. See Table 1 for the kits covered by these
instructions.
These instructions provide a step-by-step procedure to field install a Vertiv™ eSure™ Power Extend Converter using one of the kits
listed in Table 1. Installation of this kit in other systems not listed in Table 1 should not be attempted.
Table 1: Power System Mounting Bracket and Door Kit Covered by these Instructions
Mounting Bracket Kit P/N Description
60017372 For use with a P/N 545277 and P/N 520276 stand-alone distribution panel. Includes mounting brackets and door.
1.2 Tools and Material Required
Table 2 lists the items required to install this kit.
Table 2: Tools and Material Required
Description
#1 Flat Blade Screw Driver, insulated
#2 Phillips Blade Screw Driver, insulated
Torque Wrench, insulated
(capable of being set from 9.6 in-lbs to 72 in-lbs)
3/8” Drive Ratchet and Socket Set, insulated
Power Extend Converter Kit (P/N 565050)
(Model C48/58-1000B, Spec. No. 1C48581000B), quantity as needed
Vertiv™ eSurePower Extend Converter Mounting Bracket and Door Kit Installation Manual
Proprietary and Confidential © 2023 Vertiv Group Corp.
2
1.3 Mounting Bracket and Door Kit Contents
Table 3 list the items furnished as a part of the mounting bracket and door kit covered by these instructions. Before installing a
mounting bracket and door kit, check the items furnished against those listed to ensure that there are no shortages.
Table 3: Mounting Bracket and Door Kit P/N 60017372 Contents
P/N Description Qty.
60016960
1
60016961
1
60008405 Captive Nut
(factory assembled to side brackets) 4
60019268 Washer
4
233362700 6-32 x 3/8” Screw
8
60016951
1
152175 Hot Surface Label
2
60016962
1
S-0650 Nut
(factory assembled to door) 2
560958P2 Product Label
(factory assembled to door) 1
514097 Caution Label
1
421121900
1
233394000 6-32 x 1/4” Screw 1
223772500 6-32 Nut with Washer 2
214109100 #12 Flat Washer, 0.438” OD, 0.040” thick 1
214109200 #12 Flat Washer, 0.625” OD, 0.063” thick 1
60010906
1
151950
1
552423 Hook-and-Loop Fastener
(factory attached to storage pouch) 1
566026
Toggle Breaker Guard Kit, includes…
(Qty. 27) L-Shaped Guard Brackets
(Qty. 27) #6-32 x 3/16” Screws
(Qty. 27) M30.5 x 5 mm Screws
1
Vertiv™ eSurePower Extend Converter Mounting Bracket and Door Kit Installation Manual
Proprietary and Confidential © 2023 Vertiv Group Corp.
3
1.4 Mounting Bracket and Door Kit Installation Procedure
THESE INSTRUCTIONS SHOULD BE READ THROUGH COMPLETELY BEFORE INSTALLING THE KIT.
The following is a step-by-step procedure to install the kit. The procedure has been written for ease of use and to minimize the
possibility of contact with potentially hazardous energy. This procedure should be performed in the sequence given, and each step
should be completely read and fully understood before performing that step. Observe all “Important Safety Instructions” starting on
page v and also those presented in the following procedure. As each step of the procedure is completed, the box adjacent to the
respective step should be checked. This will minimize the possibility of inadvertently skipping any steps. If the step is not required to
be performed for your site, also check the box to indicate that it was read.
1.4.1 Important Safety Instructions
DANGER! Adhere to the Important Safety Instructions” starting on page v and those listed in the power system manual.
CAUTION! When performing any step in procedures that requires removal or installation of hardware, use caution to ensure
no hardware is dropped and left inside the unit; otherwise service interruption or equipment damage may occur.
NOTE! When performing any step in this procedure which requires removal of existing hardware, retain all hardware for use
in subsequent steps, unless otherwise stated.
1.4.2 Installing Mounting Bracket and Door Kit P/N 60017372
Procedure
[ ] 1. Performing this procedure may activate external alarms. Do one of the following. If possible, disable these alarms. If
these alarms cannot be easily disabled, notify the appropriate personnel to disregard any future alarms associated with
this system while the procedure is being performed.
[ ] 2. Gain access to the distribution panel into which the power extend converter is to be installed.
[ ] 3. Remove the front cover from the P/N 545277 distribution panel. See Figure 1. The front cover and mounting hardware
will not be re-used.
Vertiv™ eSurePower Extend Converter Mounting Bracket and Door Kit Installation Manual
Proprietary and Confidential © 2023 Vertiv Group Corp.
4
Figure 1: Removing P/N 545277 Distribution Panel Front Cover
[ ] 4. Orient the kit supplied left side mounting bracket as shown in Figure 2. Secure to distribution panel with kit supplied
hardware as shown in Figure 2. Torque hardware as indicated in Figure 2.
Figure 2: Install Kit Left Side Mounting Bracket
Remove Cover and Hardware
Install Left Bracket
Left Bracket
6-32 x 3/8” Screw
Torque to 9.6 in-lbs.
6-32 x 3/8” Screw
Torque to 9.6 in-lbs.
Vertiv™ eSurePower Extend Converter Mounting Bracket and Door Kit Installation Manual
Proprietary and Confidential © 2023 Vertiv Group Corp.
5
[ ] 5. Orient the kit supplied front mounting bracket as shown in Figure 3. Secure the front mounting bracket to the left side
mounting bracket as shown in Figure 3. DO NOT TIGHTEN HARDWARE (hardware will be tightened during power
extend converter installation).
Figure 3: Install Kit Front Mounting Bracket
Install Front Bracket
Front Bracket
6-32 x 3/8” Screw
(DO NOT TIGHTEN)
Vertiv™ eSurePower Extend Converter Mounting Bracket and Door Kit Installation Manual
Proprietary and Confidential © 2023 Vertiv Group Corp.
6
[ ] 6. Orient the kit supplied right side mounting bracket as shown in Figure 4. Secure the right side mounting bracket to the
distribution panel with kit supplied hardware as shown in Figure 4. Torque hardware as indicated in Figure 4. Secure
the front mounting bracket to the right side mounting bracket as shown in Figure 4. DO NOT TIGHTEN HARDWARE
(hardware will be tightened during power extend converter installation).
Figure 4: Install Kit Right Side Bracket
Install Right Bracket
Right Bracket
6-32 x 3/8” Screw
Torque to 9.6 in-lbs.
6-32 x 3/8” Screw
(DO NOT TIGHTEN)
Vertiv™ eSurePower Extend Converter Mounting Bracket and Door Kit Installation Manual
Proprietary and Confidential © 2023 Vertiv Group Corp.
7
[ ] 7. Orient the kit supplied front door as shown in Figure 5. Place upper front door mounting post into corresponding hole in
left side bracket. Place larger washer on lower post of left side bracket. Place hole in lower front door into
corresponding mounting post in left side bracket (over washer just installed). Install hardware to secure lower front door
to left side bracket as shown in Figure 5. Torque hardware as indicated in Figure 5.
NOTE! When installing a power extend converter mounting bracket kit covered by these instructions onto a stand-alone
distribution cabinet installed in an outside plant enclosure, leave the front door off the stand-alone distribution cabinet when
complete with the installation.
Figure 5: Install Kit Front Door
Door Lower
Mounting Location
Third place hole in lower front door into
corresponding mounting post in left side
bracket. Install hardware to secure lower
front door to left side bracket.
Second place larger
washer onto lower
mounting post in left
side bracket.
6-32 x 1/4” Screw
Torque to 9.6 in-lbs.
Smaller Washer
Install Front Door
Door Upper Mounting Location
First place upper front door mounting post
into corresponding hole in left side bracket.
Vertiv™ eSurePower Extend Converter Mounting Bracket and Door Kit Installation Manual
Proprietary and Confidential © 2023 Vertiv Group Corp.
8
[ ] 8. Install the door grounding strap as shown in Figure 6. Torque hardware as indicated in Figure 6.
Figure 6: Install Door Grounding Strap
[ ] 9. Remove the kit supplied distribution position label (see Figure 7) from the kit supplied storage pouch and (using the
label on the front cover removed from the distribution panel as a guide) record the distribution positions onto the kit
supplied label.
[ ] 10. Place the kit supplied distribution position label (see Figure 7) back into the kit supplied storage pouch or remove the
backing from the label and adhere it to a suitable surface near the power system. If the kit supplied distribution position
label is placed back into the storage pouch, remove the backing from the hook-and-loop fastener factory attached to the
storage pouch and adhere the storage pouch to a suitable surface near the power system.
Install Grounding Strap
6-32 Nut with Washer
Torque to 9.6 in-lbs.
Vertiv™ eSurePower Extend Converter Mounting Bracket and Door Kit Installation Manual
Proprietary and Confidential © 2023 Vertiv Group Corp.
9
Figure 7: Distribution Position Label
[ ] 11. Install the toggle breaker guard kit (P/N 566026) as required per site requirements. See Figure 8.
Figure 8: Toggle Breaker Guard Kit (P/N 566026)
[ ] 12. Continue with the “Installing the Power Extend Converter into a Distribution Position” procedure starting on page 10.
Distribution Position Label
Toggle Breaker Guard
Kit P/N 566026
Existing Circuit Breakers
Note: The circuit breaker
mounting hole diameter
varies between circuit
breaker manufactures.
Select the appropriate kit
supplied screw to mount
the guard to the circuit
breaker. Carefully match
the screw diameter to the
hole diameter.
Installed View
Vertiv™ eSurePower Extend Converter Mounting Bracket and Door Kit Installation Manual
Proprietary and Confidential © 2023 Vertiv Group Corp.
10
2 Installing the Power Extend Converter into a Distribution
Position
2.1 Important Safety Instructions
DANGER! Adhere to the “Important Safety Instructionsstarting on page v and those listed in the power system manual.
ALERT! Only install the power extend converter into a -48 VDC distribution position. Non-repairable damage will occur if the
power extend converter is plugged into a +24 VDC distribution position.
NOTE! The power extend converter can be inserted or removed with power applied (hot swappable) as long as the power
extend converter is inserted/removed with the enable/disable switch in the disabled position (see Figure 12 on page 15).
WARNING! The power extend converter and front mounting bracket becomes very hot during power extend converter
operation at heavy load. Wear heat resistant gloves or allow the power extend converter to cool down before removing.
2.2 Restrictions
Refer to the power extend converter instruction manual (UM565050) for wire sizing restrictions.
Refer to Table 4 for spacing and power restrictions. This table shows how many converters can be placed side by side before
skipping a single space at certain average power levels. These power levels pertain to the average output power (busy hour average
power) drawn by the load including any power loss in the cable. The peak power available from each unit remains at 1000 watts
regardless of spacing or location. Use the calculator tool that can be obtained at https://www.vertiv.com/en-us/products-
catalog/critical-power/dc-power-systems/esure-power-extend-converter-c4858-1000/#/downloads to determine the necessity,
quantity and spacing requirement of the Power Extend Converter based on the RRU type (or peak load), use application (host power
system), trunk and jumper cable size and length, minimum source voltage and minimum RRU operating voltage.
NOTE! When installing a power extend converter mounting bracket kit covered by these instructions onto a stand-alone
distribution cabinet installed in an outside plant enclosure, leave the front door off the stand-alone distribution cabinet when
complete with the installation.
Table 4: Spacing and Power Restrictions: Spec. No. 545277 and 520276 Operating in a 40°C Ambient
Distribution Row
Watts Per Power Extend Converter
No Spaces 1 Pole / Space 2 Pole / Space 3 Pole / Space 4 Pole / Space
Row 1 Only 375 W 900 W 750 W 600 W 500 W
ALERT! When circuit breaker(s) and Power Extend Converter(s) (Model C48/58-1000B, Spec. No. 1C48581000B) are
deployed in the same enclosure, circuit breaker(s) can only be loaded to 70% of rated value.
Vertiv™ eSurePower Extend Converter Mounting Bracket and Door Kit Installation Manual
Proprietary and Confidential © 2023 Vertiv Group Corp.
11
2.3 Preparing the Distribution Cabinet
Procedure
[ ] 1. If the power extend converter is to be installed for a newly connected load, connect the load and load return cables for
the distribution position to be occupied by the power extend converter. At the same time, connect the power extend
converter return wire faston tab (P/N 565990) provided with the power extend converter to the cabinet’s return busbar
(use the same location as the return lead to the load). At the same time (if required), connect the separately ordered
power extend converter paralleling busbar (P/N 60016097 for paralleling two converters, P/N 545346 for paralleling
three converters) to the distribution panel load busbars (use the same location as the load lead to the load). See Figure
9. Torque as indicated in Figure 9.
[ ] 2. If the power extend converter is to replace an existing circuit breaker, remove the circuit breaker and verify the load and
return cables for the position are wired and labeled correctly. At the same time, connect the power extend converter
return wire faston tab (P/N 565990) provided with the power extend converter to the cabinet’s return busbar (use the
same location as the return lead to the load). At the same time (if required), connect the separately ordered power
extend converter paralleling busbar (P/N 60016097 for paralleling two converters, P/N 545346 for paralleling three
converters) to the distribution panel load busbars (use the same location as the load lead to the load). See Figure 9.
Torque as shown Figure 9.
Figure 9: Connecting Power Extend Converter Load Return Cables to the Return Bar with the Power Extend Converter Return Wire
Faston Tab (P/N 565990) and Connecting Power Extend Converter Load Cables to the Distribution Panel with Power
Extend Converter Paralleling Busbar (P/N 60016097 or 545346) (if required) (cont’d on next page)
Distribution Panel
Return Bar
Distribution Panel
Load Busbars
Installed View Connect
Power Extend Converter
Load Return Lead Here
(Torque to 72 in-lbs)
Connect
Power Extend Converter
Load Lead Here
(Torque to 72 in-lbs)
Front View
Vertiv™ eSurePower Extend Converter Mounting Bracket and Door Kit Installation Manual
Proprietary and Confidential © 2023 Vertiv Group Corp.
12
Figure 9: Connecting Power Extend Converter Load Return Cables to the Return Bar with the Power Extend Converter Return Wire
Faston Tab (P/N 565990) and Connecting Power Extend Converter Load Cables to the Distribution Panel with Power
Extend Converter Paralleling Busbar (P/N 60016097 or 545346) (if required) (cont’d from previous page)
Power Extend Converter
Parallelling Busbar
P/N 545346
Load Lead Lug
1/4” Flat Washer
1/4” Lock Washer
(Torque to 72 in-lbs)
1/4-20 x 5/8” Bolt
Power Extend Converter
Parallelling Busbar
P/N 60016097
Load Lead Lug
1/4” Flat Washer
1/4” Lock Washer
(Torque to 72 in-lbs)
1/4-20 x 5/8” Bolt
Load Lead Lug
1/4” Lock Washer
1/4-20 x 5/8” Bolt
(Torque to 72 in-lbs)
1/4” Flat Washer
Load Return
Lead Lug
1/4” Flat Washer
1/4” Lock Washer
Power Extend Converter
Return Wire Faston Tabs
(P/N 565990)
(Torque to 72 in-lbs)
1/4-20 x 5/8” Bolt
Load Return
Lead Lug
1/4” Flat Washer
1/4” Lock Washer
Power Extend Converter
Return Wire Faston Tabs
(P/N 565990)
(Torque to 72 in-lbs)
1/4-20 x 5/8” Bolt
Load Return
Lead Lug
1/4” Lock Washer
Power Extend Converter
Return Wire Faston Tabs
(P/N 565990)
(Torque to 72 in-lbs)
1/4” Flat Washer
1/4-20 x 5/8” Bolt
Exploded View
Return Busbar
Exploded View
Return Busbar
Exploded View
Load Busbar
Exploded View
Load Busbar
Assembled View
Distribution Panel
Return Bar
Distribution Panel
Load Busbars
Front View
Vertiv™ eSurePower Extend Converter Mounting Bracket and Door Kit Installation Manual
Proprietary and Confidential © 2023 Vertiv Group Corp.
13
2.4 Installing the Power Extend Converter(s)
NOTE! See also “Restrictions” on page 10.
Procedure
[ ] 1. Move the grounding tab from the top of the power extend converter to the bottom per Figure 10. Repeat for each
power extend converter to be installed.
Figure 10: Moving Grounding Tab from Top of Unit to Bottom
[ ] 2. Connect the return wire (P/N 564330) provided with the power extend converter to a power extend converter return
wire faston tab (P/N 565990) installed on the cabinet’s return bar in a previous step. See Figure 11. Repeat for each
power extend converter to be installed.
NOTE! The furnished 4-inch long return wire jumper (P/N 565752) may be installed with the P/N 564330 return wire if
additional return wire length is preferred.
NOTE! The power extend converter is also furnished with an 8-inch long return wire jumper P/N 566207. The 8-inch long
return wire jumper is not used with this mounting bracket kit. It is used in other kits.
Move grounding tab from top of unit to bottom by removing the screw
securing it to the top. Set the grounding tab and screw aside. Remove
the bottom screw. Secure the screw removed from the bottom location
into the top location (note that it is a different length then the screw used
to secure the grounding tab). Orient the grounding tab in the bottom
location as shown in the illustration and secure with the screw removed
from the top location (longer screw). Torque both screws to 5.8 in-lbs.
M3 x 6 mm
Flat Head Screw
M3 x 4 mm
Flat Head Screw
M3 x 6 mm
Flat Head Screw
M3 x 4 mm
Flat Head Screw
Vertiv™ eSurePower Extend Converter Mounting Bracket and Door Kit Installation Manual
Proprietary and Confidential © 2023 Vertiv Group Corp.
14
Figure 11: Connecting Power Extend Converter Return Wire(s) (P/N 564330) to a Power Extend Converter Return Wire Faston Tab
(P/N 565990) and to a Power Extend Converter
Power Extend Converter
Return Wire (P/N 564330)
Power Extend Converter
Return Wire Faston Tab
(P/N 565990)
Power
Extend
Converter
Power
Extend
Converter
Orient the white square on
the return wire faston
receptacle’s locking tab so
it is visible. This allows
easy access to remove the
return lead if required.
Installed View
Exploded View
Note: Power Extend Converter
Return Wire Jumper (P/N 565752)
may be used here if increased
return wire length is desired.
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Vertiv IM60017372 User manual

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